Container



Dec. 9, 1952 v. HAsoPlAN 2,620,963

CONTAINER Original Filed March 18, 1944 2 SHEETS-SHEET 1 V. HAGOPIAN Dec. 9, 1952 CONTAINER 2 SHEETS-SHEET 2 i v I w n a Z W "I a a T Patented Dec. 9, 1952 CONTAINER Vahan Hagopian, New York, N. Y., assignor to The Plastic Barrel Corporation, New York, N. Y., a corporation of New York Original application March 18, 1944, Serial No.

527,035, now Patent No. 2,460,820, dated February 8, 1949. Divided and this application December 16, 1948, Serial No. 65,629

13 Claims. (01. 229-67) This invention relates to containers, such as barrels, and has particular reference to containers of plastic material, and this application is a division of copending application Serial No. 527,035, filed March 18, 1944, now Patent No. 2,460,820, issued February 8, 1949.

Heretofore, liquid containers made of plastic material, such as paper stock and other similar fibrous material, or combinations of sheet material and adhesive or binding agent, such as wood, cloth, fiber, or paper strips bonded together with initially plastic adhesive and the like, have either not been sufficiently strong to withstand shipping and if made strong, have required a disproportionate degree of hand work, usually resulting in increased cost, non-uniform products, and considerable expense, and hence have not been successful on a commercial scale, except when special products of high cost were justified by requirements. container of plastic material which is strong enough for transporting and dispensing liquids of virtually any description, would have considerable value.

In accordance with the present invention, a strong, rigid hollow shell usable for any purpose, such as a barrel or other container of inexpensive and readily available raw material is provided for shipping or storing various materials, particularly liquids. More particularly, the container of this invention comprises forming cu shaped rudimentary plies of felted material, such as paper stock, or other vegetable fibers, such as hemp, jute, cotton, and the like, animal fibers or mixtures of the vegetable and animal fibers, by a conventional process of wet felting on a foraminous form or screen, impregnated with a suitable adhesive, preferably a thermo-responsive adhesive, such as a phenolic, urea, vinyl, or other similar synthetic resin and adhered together with their free edges overlapped, internal pressure by an inflated bag forcing the plies against a heated die setting the plies in rigid unitary form, with the bag adhering to the interior of the hollow shell thus formed to constitute a permanent impervious liner therefor. The bag-inflating medium may be a heated fluid, such as steam, if thermo-responsive adhesive is used, and in that case the bag preferably is also formed of thermoplastic material so as to soften and become bonded to the interior of the container, to thereby serve as the permanent fluid-impervious liner therefor, thus simultaneously assuring liquid tightness of the container and rendering the same immune to deterioration from many liquids that may be stored therein.

Consequently, a barrel or similar The hollow shell thus formed is substantially a finished product when withdrawn from the die and the double-thickness of its wall around its center portion augments its strength at that point where it is most needed in the case of a barrel, particularly in the case of large barrels which are commonly dropped and rolled on the bilge when being handled. In order to increase the strength of the chine in the case of a barrel, a preformed reinforcing ring is inserted between the plies at each end before molding, and these rings also serve to emphasize the chine, thus simulating the projecting chine on a conventional stave-type barrel.

It will be seen that a container of this invention has novel seamless construction, fluid-tightness, lightness and strength, and may be made uniformly in quantity at low expense by the method of this invention.

For a more complete understanding of this invention, reference may be had to the accompanying drawings, in which:

Figure 1 illustrates an example of the container of this invention, as seen in axial section,

and

Fig. 2 illustrates the preferred apparatus for making the container of this invention.

Referring to Fig. 2 of the drawings to illustrate the construction of the novel container, numerals H! to IE, inclusive, designate cup-shaped rudimentary plies, each comprising a felted or otherwise conformed mass of natural or artificial fibrous material, such as' paper stock, wood fibers including the lignin, hemp, sisal, jute, tow fiber, cotton, or other Vegetable fibers, animal fiber, such as hair, or mixtures of animal and vegetable fiber, the fibers being sufficiently closely felted or compacted, or both, to render the cup-shaped plies self-sustaining and capable of being handled for assembly purposes without disintegration or tearing. Such cup-shaped plies are formed by the conventional dry or wet felting process. In the latter, a slurry of water and the ,fiber. is drawn against the surface of a foraminous form or screen of. the desired contour, and when a sufficiently thick layer has been collected on the screen, the layer is ejected by pressure from within the screen and then stripped oil and dried. Because the plies so'formed are relatively loosely felted, they may be stretched to some extent and thus may be made of uniform initial size for making a particular container.

Preferably the dried plies ill to [5 are impregnated with a suitable thermo-responsive resin, such as a phenolic or urea condensation product, vinyl resin, or the like, or the plies may be coated therewith as by spraying with an aqueous mixture or solution of the resin, and then dried. It is also to be understood that although thermoresponsive adhesives are preferred, so-called wet or cold-setting adhesives such as casein, dextrin or animal or fish glues and the like, may also be used, depending on the use to which the container is to be put. However, the use of thermo-responsive type of adhesive will be contemplated herein, to illustrate but not limit the method of this invention.

The adhesive-impregnated or coated plies are then nested in sets of one or more, preferably not less than three per set, as indicated in Fig. 1, wherein one set, designated A, is shown as composed of plies I0, II and I2, and the other set, designated B, being composed of plies I3, I4 and I5.

One set of nested plies, such as A, will contain the access opening or opening of the finished container, such as the bung in the case of a barrel, with or without an additional air vent. Considering a container having a small opening such as a bung in the head, positioned at the desired point, the set A is perforated through the three plies for the reception of a nipple I6 of metal or plastic. The nipple I6 is provided at one end with a flange I! having a roughened interior surface to bite into the adjacent plies and thus prevent the nipple from turning. The shank I8 is exteriorly and interiorly threaded, as shown in greater detail in Fig. 2.

Before being inserted into the bung opening in plies of set A, the edge of an opening in a fluidtight bag I9 is cemented or otherwise permanently sealed pressure-tightly to the outer or inner surface of flange I! of nipple I6. The bag I9 is made of elastic material, such as rubber, coated on the outside so as to be adhesive, or the adhesive may be that with which the inner plies I and I3 are impregnated or coated, so that when inflated, the bag I9 lies coextensively with the inner surface of the container and becomes adhered thereto. Preferably, however, th bag I9 is, composed of material which, while somewhat elastic, becomes more so when heated, and if sufficiently heated, softens so as to become adhesive. An example of such material is polyvinyl chloride, but other material having similar properties may beemployed with equal facility.

The ply set A, with the nipple I6 inserted through the bung opening, may be placed in the lower half 20 of a split die D having an opening 2I for the nipple shank I8, into the interior of which has been screwed flexible supply pipe 22 which is then connected by union 23 to pipe 24, which is connected to header 25 controlled by valve 26. Then the second set of plies B is inverted over the first set A and the free edges of the one set inserted between the edges of the plies of the other set so that the plies of both sets interfit and partially overlap. Thus, as shown in Fig. 1, the edge of ply I4 lies between the edges of plies I0 and II; the edge of ply I I lies between the edges of plies I3 and I4, and so on. If more convenient or desirable, the plies of the two sets A and B may be assembled together as described, before being inserted in the lower die half 20.

The di D, comprising lower half 20 and upper half 21, is shaped to the contour desired for the finished product, such as the barrel shown. The die D is relieved at 28 to accommodate the doubled thickness of the stock at the bilge due to the overlapping of the edges of the plies at that point, as described. The die D may also be relieved at 29 to provide the chine of the finished barrel, as shown, and the lower die half 20 is preferably provided with a registering tongue 30 which fit into the groove (H in the upper die half to assure alignment when the upper die half 21 is lowered on the lower die half 20.

Latches 32 on the lower die half 20 cooperate with lugs 33 on the upper half 21 to lock the die D closed when in operation, but no attempt is made to seal the die airtightly, but on the contrary, the joint between the die halves should not be air tight, so as to permit the air and steam to be purged therefrom as the bag I9 is inflated. Other vent holes in the die may be provided if desired.

When the adhesive employed is of the thermoresponsive type, as herein contemplated for purposes of illustration, the die D is heated, preferably by steam, which is supplied from header 25 and pipe 35 to the jacket 34 surrounding lower die half 20, and to the jacket 31 surrounding the upper die half 21 by pipe 38 and flexible hose 39. A normally closed purge valve 40 is provided, for exhausting die jackets 34 and 31 and bag I9 after the bonding operation is complete. The pipes 24, 35 and 38 may also be provided with individual flow and pressure control valves if required. The die D may be electrically heated instead, if desired.

In making the container of this invention, the plies II] to I5, impregnated with the dry thermoresponsive adhesive and assembled in the manner described, are enclosed in the die D and steam is supplied thereto and to bag I9 by opening valve 26. The bag I9 expands and forces the plies into conformity with the contour of the die D, while the adhesive becomes plastic in response to the heat applied thereto. The bag I9 also softens and becomes adhesive, so as to bond itself coextensively to the interior surface of the container.

After heating for a predetermined time, depending upon the adhesive used, the size of the article being molded and the molding pressure being used, the steam is turned oif by closing valve 26 and the steam exhausted from die jackets 34 and 37 and bag I9 by opening valve 40. After cooling and when the adhesive is set, the finished container is removed from the die D after uncoupling union 23 and then disconnecting pipe 22 from the nipple I6. A flat not H may then be screwed down on the shank I8, over a washer 42, to complete the barrel, as shown in Fig. 1.

As indicated, the hollow shell thus formed may have any desired shape or contour required for its intended function. Thus, if intended for use as a, container of the barrel shape shown in Figs. 1 and 2, it may be provided either with a center bung, as in Fig. 2, or an offset bung, as in Fig. 1, or with any one or more desired different openings. For liquid-containing barrels, kegs, carboys, etc., or for any other purpose, the container is provided with the permanent fluid-impervious liner, formerly the bag I9, as shown in Fig. 1. Also, as shown especially in Fig. 1, the plies I G to I5 are reduced in thickness by the pressure and the double-thickness plies at the equator form a relatively thick band 26' which imparts augmented strength to the hollow shell thus formed without materially increasing its weight or size, and, in the case of a barrel, the band 28 may be bulged outwardly as shown and thus serve as the bilge of the barrel. The Wallet the hollow shell, being made of fibers and plastic, is very strong, substantially rigid and essentially homogeneous and, as indicated, may serve any purpose, in whole or in part. Selected zones of the hollow shell, such as the chine 29 in the case of a barrel may be strengthened and emphasized by incorporating between theplies at that point a ring 4| of steam-bent wood, plywood, precompressed fiber or other suitable material, further reinforced with metal wire, if desired. Other modifications of the product of this invention may be made within the scope of the appended claims in which the term container is used to denote a hollow shell having substantially rigid walls, for any use.

I claim:

1. As a new article ofmanufacture, a barrel having a wall formed of two sets of nested cupshaped plies having the free edges of one set alternately overlapping the free edges of the other set, a solid bilge therefor having a greater number of plies than said wall, a reinforcing ring between the plies at the ends of the barrel forming chines therefor, and a fluid-impervious bag adhered coextensively to the inner wall of the barrel.

2. As a new article of manufacture, a bag of fluid-impervious material having insufiicient rigidity to maintain a predetermined shape, a substantially rigid enclosure therefor comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having its interior surface conforming to said predetermined shape, and means coextensively uniting the exterior and interior surfaces of said bag and enclosure, respectively.

3. As a new article of manufacture, a bag of plastic material having insufficient rigidity to maintain a predetermined shape, a substantially rigid enclosure therefor comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having its interior surface conforming to said predetermined shape, and means coextensively uniting the exterior and interior surfaces of said bag and enclosure, respectively.

4. As a new article of manufacture, a flexible bag having a filling and discharge opening, a substantially rigid enclosure for said bag having an interior surface area slightly less than the exterior surface area of said bag, said enclosure comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having an opening corresponding to said bag opening, and closure means securing said bag around the opening therein to said enclosure in registry with the opening therein.

5. As a new article of manufacture, a flexible bag having a filling and discharge opening, a substantially rigid enclosure for said bag having an interior surface area slightly less than the exterior surface area of said bag, said enclosure comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having an opening corresponding to said bag opening, means coextensively uniting the respective exterior and interior surfaces of said enclosure and said bag, and closure means securing said bag around the opening therein to said enclosure in registry with the opening therein.

6. As a new article of manufacture, a bag of fluid-impervious material having insufficient rigidity to maintain a predetermined shape, a substantially rigid enclosure therefor comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having its interior surface conforming to said predetermined shape, means coextensively uniting the exterior and interior surfaces of said bag and enclosure, respectively, said bag and enclosure each having a registering filling and discharge opening, and closure means for said opening.

'7. As a, new article of manufacture, a bag of fluid-impervious material having insufiicient rigidity to maintain a predetermined shape, a substantially rigid enclosure therefor comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having its interior surface conforming to said predetermined shape, means coextensively uniting the exterior and interior surfaces of said bag and enclosure, respectively, said bag and enclosure each having a registering filling and discharge opening, and a nipple secured in said opening.

8. As a new article of manufacture, a bag of fluid-impervious material having insufficient rigidity to maintain a predetermined shape, a substantially rigid enclosure therefor comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set and having its interior surface conforming to said predetermined shape, means coextensively uniting the exterior and interior surfaces of said bag and enclosure, respectively, said bag and enclosure each having a registering filling and discharge opening, a nipple having an external flange at its inner end within said opening with said flange engaging the surface of said bag at the periphery of said opening, and means on said nipple engaging the outer surface of said enclosure at the periphery of said opening to secure the nipple in place.

9. As a new article of manufacture, a container of resin-impregnated fibrous material comprising two sets of nested cup-shaped plies having the free edges of one set interleaved with the free edges of the other set, a fluid-impervious liner therefor comprising a bag adhered coextensively to the inner surface thereof, said bag and enclosure each having a registering filling and discharge opening, and closure means for said opening.

10. As a new article of manufacture, a hollow body formed of two sets of nested cup-shaped plies having the free edges of one set alternately overlapping the free edges of the other set in complete complementary fashion, a bag of elastic material therein, and means coextensively uniting the respective exterior and interior surfaces of said bag and body.

11. As a new article of manufacture, a container comprising two sets of a plurality of nested cup-shaped plies of fibrous material telescoped one set within the other with the concave sides of the sets facing each other and the free edges of the plies of one set alternately interposed between the free edges of the plies of the other set in overlapping and wholly complementary relation, means uniting the plies of each set and the said overlapping free edges, and a fluid impervious bag adhered to the inner walls of the innermost plies and having a filling and discharging opening therein.

12.. As a new article of; manufacture, a con;- tainer comprising two sets of nestedv cup-shaped resin-impregnated fibrous multiple plies having the free edges of one set alternately overlapping the free edges of the other set, a solid bilge formed by said overlapping free ends, and a fluidimpervious liner comprising a bag adhered coextensively to the inner surface of said container.

13. As a new article of manufacture, a barrel or the like, comprising two sets of plies of felted fibers impregnated with an adhesive to bind the fibers and plies together, the plies of each set being telescoped one within the other with the concave sides of the sets facing each other and the free edges of the. plies of one set alternately interposed between the free edges of the plies of the other set in overlapping relation, said interposed plies conforming; closely to each, other and, having scarfed edges to, form a substantially homogeneous and a void-free joint between said plies, the plies of each set and said overlapping free edges being joined by said adhesive.

VAHAN HAGOPIAN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 616,037 Thomson Dec. 13, 1898 1,367,231 Boyer Feb. 1, 1921 1,452,039 Gravell Apr. 17, 1923 1,632,187 Koch June 14, 1927 1,725,525 Kondolf Aug. 20, 1929 2,118,565 Meade May 24, 1938 2,215,268 Himmer Sept. 17, 1940 2,274,095 Sawyer Feb. 24, 1942 2,338,604 Silveyra Jan. 4, 1944 

